Container



Jan. 17, 1961 c. J. CANTRELL, SR 2,968,397

CONTAINER Filed Feb. 24, 1958 5 Sheets-Sheet 1 ATTORNEY.

17, 1961 c. J. CANTRELL, s 2,968,397

CONTAINER Filed Feb. 24, 1958 5 Sheets-Sheet 2 INVENTOR.

CLAUDE J. CANTRELL,SR.,

zw/M

ATTQRNEY.

CONTAINER S Sheets-Sheet 3 Filed Feb. 24. 1958 FIG. 3.

INVENTOR.

CLAUDE J. CANTRELL,SR., M

ATTORNEY United tate P ten CONTAINER Claude J. Cantrell, Sr., Baytown, Tex., assignor, by mesne assignments, to Esso Research and Engineering Company, Elizabeth, N.J., a corporation of Delaware Filed Feb. 24, 1958, Ser. No. 717,195

2 Claims. (Cl. 206-65) This invention relates to a shipping container for a plurality of bales of unvulcanized rubbery isoolefindiolefin copolymer.

Unvulcanized rubbery isoolefin-diolefin copolymers such as isobutylene-isoprene copolymers of' the Butyl rubber type are not dimensionally stable and are subject to cold flow at ambient temperatures. Still further, the unvulcanized copolymer is tacky at ambient temperatures. In order to compensate for the tackiness problem, it has been customary to wrap a plurality of sheets of unvulcanized copolymer in a thin, flexible continuous self-sustaining film of a non-adherent polymer such as polyethylene, styrene-isobutylene copolymer, etc. to thereby form a bale of the copolymer. As a practical matter, it is necessary to limit the weight of such bales to weights within the range of about 40 to 80 pounds in order to prevent undue distortion of the bale due to cold flow.

It has been the customary practice, due to the cold flow problem, to individually pack bales of this nature in individual paperboard containers. This, in turn, has presented a serious problem due to the large amount of handling required for the stacking, unloading, etc. of the comparatively small size boxes.

The problem of cold flow with respect to multi-bale cartons of Butyl type polymer is overcome in accordance with the present invention through the provision of a container comprising a lower open-topped, stiiiened box member; a plurality of rectangular open-topped tubular bale holders loosely arrange within said lower box member, each such bale holder being adapted to contain a plurality of bales of Butyl type rubber, each such tubular holder having a cross-sectional configuration greater than the cross-sectional configuration of the bales to be contained therein; a partition member comprising a central dividing panel provided with a peripheral flange adapted to telescopically fit said lower box member and to extend above said panel; an open-ended rectangular upper box member adapted to snugly, telescopically fit within the upper flange of the partition member; a plurality of said tubular bale holders adapted to loosely fit within said upper box member and a downwardly flanged cover member adapted to snugly, telescopically fit the upper portion of said upper box member.

A shipping container of the just-described construction may be advantageously constructed so as to contain a number of bales of Butyl type polymer sufiicient to provide a load for a fork truck whereby palleting may be eliminated and whereby storage and handling of the Butyl rubber bales may be greatly facilitated.

The invention will be further illustrated by reference to the accompanying drawings wherein:

Fig. 1-is an exploded perspective view, with parts broken away, showing a preferred form of the present invention;

Fig. 2 is a perspective view, with parts broken away, showing the interrelationship of the components of the carton shortly after loading of the same; and

Fig. 3 is a perspective view, with parts broken away,

- showing the manner in which the problems of cold flow are overcome in accordance with the present invention.

Turning now to the drawings, wherein like numerals refer to like parts, there is disclosed a container designated generally by the numeral 10 formed from paperboard, surface reinforced expanded polystyrene, etc., or

a similar type material.

The container 10 comprises a lower box member designated generally by the numeral 12, which comprises side walls 41, end walls 16, bottom side flaps 18, and bottom end flaps 20.

In assembling the lower box member 12, the end flaps 20 are folded in, as shown in Fig. l, and a single-ply U-shaped, snugly fitting bottom plate 22 is inserted. Thereafter, the bottom side flaps 18 are folded over and sealed.

Next, snugly fitting, U-shaped side plates 24 are inserted to thereby provide for a reinforced lower box member 12.

Next, a plurality of tubular bale holders 26, open on one end, are inserted in the lower box member 12, the bale holders 26 being proportioned so as to loosely fit within the lower box member 12 for a purpose to be described. In addition, each of the bale holders 26 should have a cross-sectional configuration equivalent to, but at least 10 percent larger in area than, the crosssectional area of the bales to be placed therein.

A partition member designated generally by the numeral 30 is provided. The partition member 3t) is comprised of a lower cover member comprising a horizontal plate 32, downwardly extending side flaps 34, and downwardly extending end flaps 36. An upper member comprising a horizontal plate 32', upwardly extending side flaps 34', and upwardly extending end flaps 36' is secured to the lower cover member in backto-back relationship in any suitable manner. Thus, the horizontal plates 32 and 32' may be glued together as shown. The partition member 30 should be proportioned so as to snugly, telescopically fit over the top of the lower box member 12.

Snugly, telescopically fitted within the upper portion of the partition member 30 is an upper box member designated by the numeral 4! identical to lower member 12. The upper box member comprises side walls 42, end walls 44, bottom side flaps 4646, and bottom end flaps 48 which are folded in and secured together to provide an open-topped box member. A plurality of loosely fitting tubular bale holders 26 constructed in the described manner are inserted within the upper box member 40.

The top closure for the container 10 is a cover plate designated generally by the numeral 50 comprising a top plate 52, downwardly extending side flaps 54, and downwardly extending end flaps 56, the cover member 50 being proportioned to snugly, telescopically fit the top of the upper box member 40.

Turning now more specifically to Fig. 2 there is shown an assembled container 10 of the present invention which has been freshly packed by inserting a plurality (e.g., 4) of bales 60 of Butyl type rubber in each of the tubular bale holders 26. It will be observed that the U-shaped reinforcing members 22 and 24 of the lower box member 12 snugly fit against the walls of the lower box member 12 but that the tubular bale holders 26 loosely fit therein.. It will be further observed that each of the bale holders the coextensive tops of the lower box member 12, the U-shaped reinforcing members 24, and the tubular bale holders 26. Thus, at this point the lower box member 12 is neither snugly nor completely filled by the bales 60.. The partition member 30, positioned over the upper most bale 60 of the bale stacks, is spaced from the top of the lower box member 12, with the side plates 34 and end plates 36 being in telescopic engagement with the walls of the lower box member 12.

The upper box member 40 is snugly fitted within the upper portion of the partition member 30 but, again, the bale holders 26 loosely fit within the upper box member 40 and, again, the bales 60 loosely fit within the bale holders 26.

The cover member 50 rests upon the uppermost bale 60 with the flaps thereof telescopically fitted over the tops of the upper box member 40.

During the storage or handling of a multibale carton of the type just described, cold flow of the Butyl type polymer will occur in each of the bales and, as a result, the shape of each of the bales Will be distorted. Thus, after the passage of a comparatively short period of time (e.g., 3 days), the container will have the appearance shown in Fig. 3. With reference to Fig. 3, it will be noted that the bales 60 now snugly fit within and abut against the walls of the bale holders 26 and that the superimposed bales within each of the bale holders 26 are coextensive in height with respect to the bale holders 26. In addition, the bale holders 26 now abut and snugly fit within the box members 12 and 40. Still further, the partition member 30 and the cover member 50 rest upon the open ends of the box members 12 and 40, respectively.

As adduced from the foregoing description, it is to be observed that the volume of Butyl rubber contained within each of the tubular bale holders 26 does not change but that the cross-sectional configuration of the superimposed bales does change. Thus, the tubular bale holder 26 should be proportioned so as to have a volume substantially equal to the volume of the bales of Butyl rubber to be inserted therein. However, and as indicated, the cross-sectional area of each of the tubular bale holders should be at least about percent greater than the cross-sectional area of the bale. Correspondingly, therefore, the height of the tubular bale holder will be about 20 percent less than the original height of the superimposed bales.

It is seen from the foregoing that an eflicient shipping carton is provided in accordance with the present invention which does not require excessive reinforcing, being almost exclusively of single ply construction, and that the carton progressively increases in strength with the passage of time whereby the cold flow properties of the Butyl type rubber are utilized to assist in the provision of a structurally sound container which may be shipped for long distances and subjected to normal handling procedures without rupture.

Having described my invention, what is claimed is:

1. A self-consolidating paperboard shipping container comprising a lower rectangular, open-topped box member, a plurality of rectangular open-topped lower tubular bale holders of predetermined volume loosely positioned within said lower box member, a lower stack of correspondingly rectangular bales of a rubbery unvulcanized polymer subject to cold flow within each of said bale holders, each of said lower stacks having a volume substantially equal to the volume of the corresponding lower bale holder and an initially smaller cross-section whereby the top of each of said lower stacks initially extends above the top of the corresponding lower bale holder, a partition member having a lower flange adapted to telescopically snugly engage the side walls of said lower box member and an upper flange defining an upper support section, said partition member being initially positioned on the tops of said lower stacks, an upper box member telescopically seated in said upper flange of said partition member, a plurality of rectangular open-topped upper bale holders loosely fitted within said upper box member, an upper stack of correspondingly rectangular bales of a rubbery unvulcanized polymer subject to cold flow within each of said upper bale holders, each of said upper stacks having a volume substantially equal to the volume of the corresponding upper bale holder and an initially smaller cross-section whereby the top of each of said upper stacks initially extends above the top of the corresponding upper bale holder, and a downwardly flanged cover member telescopically fitted on the top of said upper box member, whereby on cold flow of said unvulcanized polymer during storage, said stacks of bales of rubbery polymer will fill said bale holders and settle to consolidate said shipping containers and to seat said partition member on said lower box member, each of said bales weighing from about 40 to pounds.

2. A self-consolidating paperboard shipping container comprising a lower rectangular, open-topped box member, a U-shaped reinforcing panel in the bottom of said box member, U-shaped side reinforcing members snugly abutting the sides of said lower box member, a plurality of rectangular open-topped lower tubular bale holders of predetermined volume loosely positioned within said lower box member, a lower stack of correspondingly rectangular bales of a rubbery unvulcanized polymer subject to cold flow within each of said lower bale holders, each of said lower stacks having a volume substantially equal to the volume of the corresponding lower bale holder, an initial cross-section at least about 10 percent less than the cross-sectional area of said lower bale holder and an initial height at least about 20 percent greater than the height of said lower bale holder whereby the top of each of said lower stacks initially extends above the top of the corresponding lower bale holder, a partition member having a lower flange adapted to telescopically snugly engage the side walls of said lower box member and an upper flange defining an upper support section, said partition member being initially positioned on the tops of said lower stacks, an upper box member telescopically seated in said upper flange of said partition member, a plurality of rectangular open-topped upper bale holders loosely fitted within said upper box member, an upper stack of correspondingly rectangular bales of a rubbery unvulcanized polymer subject to cold flow within each of said upper bale holders, each of said upper stacks having a volume substantially equal to the volume of the corresponding upper bale holder, an initial cross-sectional area at least about 10 percent smaller than the cross-sectional area of said upper bale holder and a height at least about 20 percent greater than the height of said upper bale holder whereby the top of each of said upper stacks initially extends above the top of the corresponding upper bale holder, and a downwardly flanged cover member telescopically fitted on the top of said upper box member, whereby on cold flow of said unvulcanized polymer during storage, said stacks of bales of rubbery polymer will fill said bale holders and settle to consolidate said shipping containers and to seat said partition member on said lower box member, each of said bales weighing from about 40 to 80 pounds.

References Cited in the file of this patent UNITED STATES PATENTS 487,085 Buehl Nov. 29, 1892 1,826,197 Adams Oct. 6, 1931 2,312,846 Olvey Mar. 2; 1943 2,564,948 Beck Aug. 21, 1951 2,656,089 Fallert Oct. 20, 1953 2,687,231 Somers Aug. 24, 1954 

